High-speed machining is a proven technique characterized by low cutting forces and high metal removal rates. High-Speed Milling is a CNC milling technique that combines high spindle speeds with increased feed rates, resulting in a high chip-forming rate and lower milling forces. This produces an improved surface quality and closer tolerances.
High-Speed Uses: Machining Titanium Rotors
In high speed milling, the electronics can make all the difference. The right CNC coupled with other elements of the control system can let a slower machine mill a given form faster than a machine with a higher top feed rate.
Axis Movement Systems for High Speed CNC Milling Machines
High-speed CNC milling is used in a variety of applications, including machining the titanium rotors of the first high-pressure compressor stages of the EJ200 engine. High speed CNC milling allows cost-effective milling of the airfoil geometry from the solid. By subsequent finishing operations, the desired surface finish is achieved. The CNC milling which caters to high speed must be structured with an axis movement system that is suitable for machining.
Advantages of High-Speed CNC Milling Machines for 3D Surfaces
The high-speed CNC milling machines required for the process must be fitted with an axis movement system suitable for machining blisks, which should be at least 5 axes simultaneously, depending on the milling task involved, and an efficient high-speed control system.
What High-Speed Control Can Do: Faster Work Output
High Speed CNC milling machines working on 3D surfaces in any material produce a finer surface finish and higher accuracy in less time than traditional milling machines. Acceleration is the most critical factor that affects high-speed machining. Since one or more axes are always increasing or decreasing velocity in a 3-D cut, the ultimate feed rate is directly related to acceleration.
Downsides of High Speed Milling: Accuracy Challenges
A CNC milling machine that possesses a higher structural stiffness has a greater potential acceleration rate. Box-shaped high-speed CNC milling machines, like Bridge and Gantries, are the most widely used types of High-speed CNC milling tools. The overhead-type Gantry exudes the highest stiffness, acceleration, and accuracy among other high-speed CNC milling tools. Due to its scalability, this machine type is available in sizes to match the workpiece, from small to large.
Look-Ahead Capability to Improve High Speed Milling Accuracy
In drilling and tapping, high-speed machining can result in faster hole-to-hole times, quicker spindle reversals for tapping, and substantial cycle-time reductions. The most dramatic benefits, though, come in 3D design machining. Few drilling and tapping jobs require a million lines of machine codes. In molds, dies, patterns, and prototypes, complex surfaces comprising a million or more line segments are not at all uncommon. Saving just a fraction of a second per move can result in substantial cycle-time improvements.
Additional Benefits: Improved Accuracy, Better Fit, and Longer Tool Life
However, despite all these benefits, in high-speed milling, the tool path segments can be so short that a machining center moving at a high feed rate can’t accelerate or decelerate fast enough to make direction changes accurately. Corners may be rounded off, and the workpiece surface may be gouged. Look-ahead is one answer. Look-ahead capability can let the CNC read ahead a certain number of blocks in the program, to anticipate sudden direction changes and slow the feed rate accordingly.
High Speed Milling Machines as a Cost-Effective Solution
In addition to the benefits mentioned above, high-speed milling also offers improved accuracy, better fit, superior finish, longer tool life, and the ability to produce more work in less time. By improving accuracy and finish, high-speed milling can reduce polishing and fitting time, and tools simply last longer because their chip load is more consistent.
SINCO-CNC offers a wide range of precision machining services for various materials such as aluminum, steel, copper, plastic, and PEEK. Our services include:
- Aluminum CNC Machining
- Steel CNC Machining
- Copper CNC Machining
- Plastic CNC Machining
- PEEK CNC Machining
At SINCO-CNC, we have skilled professionals who are proficient in CAD and CAM software, as well as advanced equipment and tools. With our precision machining services, we can produce parts that meet